MAINTENANCE

IMPORTANT: • Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment may effect the machine’s electronic parts, causing involuntary movement of the machine. Also, improper installation of electrical equipment may cause unexpected machine failure and/or fire on the machine. Be sure to consult your nearest TCM dealer when installing radio communication equipment or additional electrical parts.

• Never attempt to disassemble or modify the electrical/electronic components. If replacement or modification of such components is required, contact your nearest TCM dealer.

Check Monitor Function and All Other Instrument Operation

--- every 10 hours (daily)

Run the engine at low idle speed when checking the instruments.

The monitor indicates alarm, caution and confirmation status in red, orange, and normal operative condition in blue or green respectively.

Check the needle movement of each gauge and meter with the key switch ON. The needle shall be moved to the blue range when normal and to the red range when abnormal. Refer to the “Operator’s Station” for more information.

Maintenance

Check Work Lights --- every 10 hours (daily) d CAUTION: If any burned-out lights are found, immediately replace it with a new one.

Visually check that all work lights normally light and/or blink from the front and rear sides of the machine.

Check Horn, Backup Buzzer and Backup Light --- every 10 hours (daily) d WARNING: Before checking the horn and/or the backup buzzer, always apply the parking brake and clear all personnel from the machine’s vicinity.

The horn switch button is located at the steering wheel center. Horns (1) are located at the left and right side of the front work light bracket.

Check that the backup buzzer (2) sound and backup light (3) ON when moving the FNR lever to reverse (R) position. Backup light (3) is located at the right side of the weight center. Backup buzzer (2) is located of the weight center.

Maintenance

Check Electrical Harnesses and Fuses

--- every 50 hours d CAUTION: If dirt or dust is adhered to the wirings and relays, it possibly results in fire.

Check the electrical harness and terminals of the batteries, battery relays, starter motor and alternator for loose connections and/or short circuit (broken shield). Clean any dirt and dust.

If any burned mark or an abnormal smell is noticed on a harness, consult your nearest TCM dealer.

Check and Replace Fuse

1. If any electrical equipment becomes inoperable, first check the fuses in base machine fuse box (1) located on the behind the operator’s seat.

2. One each spare fuse for respective fuse capacities is provided in the fuse box.

3. Finally, check slow blow fuses (2) (2 used) located in the left front of the engine room.

Slow blow fuses (2): 100 A (2 used)

Maintenance

Fuse Box

No.Ampere Corresponding Circuit

110HEAD LIGHT (LEFT)

210HEAD LIGHT (RIGHT)

315HEAD LIGHT (HI BEAM)

45CLEARANCE LIGHT (LEFT), TAIL LIGHT (RIGHT)

55CLEARANCE LIGHT (RIGHT), TAIL LIGHT (LEFT)

615 HST [F], [R] SOLENOID, PARKING BRAKE SOLENOID, BACKUP LIGHT, BACKUP BUZZER, RELAY [1], RELAY [2]

715HORN, BRAKE LAMP

810ENGINE STOP SOLENOID, FUEL PUMP

910SAFETY RELAY, ALTERNATOR, ENGINE SPEED SENSOR, RELAY [3]

1010BUCKET AUTO LEVELER PROXIMITY SWITCH, CONTROL VALVE DETENT (TILT)

1110MONITOR

1230HEAD LIGHT, CLEARANCE LIGHT, TAIL LIGHT

1315HST CONTROLLER

1410MONITOR BACKUP POWER SUPPLY

Maintenance

Battery

d WARNING: Explosive gas is generated during use and/or charging of batteries. Keep sparks and Open flames away from batteries. Do not continue to use or charge the battery when electrolyte is lower than the specified level. Explosion of the battery may result. Charge the batteries in a well ventilated location. Dilute sulfuric acid used for electrolyte is strong enough to burn skin and eats holes in clothing and metal. Always be careful when handling the batteries.

IMPORTANT: If the battery is used with the electrolyte level lower than the specified lower level, the battery may deteriorate quickly.

IMPORTANT: Do not refill electrolyte more than the specified upper level. Electrolyte may spill, damaging the painted surfaces and/or corroding other machine parts.

fNOTE: In case electrolyte is refilled more than the specified upper level line or beyond the bottom end of the sleeve, remove the excess electrolyte until the electrolyte level is down to the bottom end of the sleeve using a pipette. After neutralizing the removed electrolyte with sodium bicarbonate, flush it with plenty of water, otherwise, consult the battery manufacturer.

Precautions for Handling Batteries

fNOTE: A battery terminal (with a black cap) located on the center of the counterweight is the ground terminal.

• If electrolyte spills on your skin and/or clothes, immediately flush the skin and/or clothes with water and then wash further with soap. If splashed in eyes, flush with water for approximately 15 minutes and seek immediate medical attention.

Maintenance

• Avoid using fire hazards such as matches lighters and tobacco near the batteries. Do not allow sparks to fly.

• Check and service the batteries only after stopping the engine, turning the key switch OFF and removing the battery caps.

• Contact of the battery immediately after operation may cause personal injury. Wait for the battery to cool.

• When the battery is recharged, inflammable hydrogen gas is created. Remove the battery from the base machine. Recharge the battery after removing the caps in a well ventilated area.

• When disconnecting the battery terminals, first disconnect the ground line [minus (-)] side terminal. When connecting the battery terminals, connect the ground line [minus (-)] side terminal last. If a piece of metal, such as a tool comes in contact with the battery plus (+) side terminal and the vehicle frame when both terminals are connected, the electrical system may shortcircuit, possibly creating a dangerous situation.

• Loose terminal may allow sparks to fly. Securely tighten the terminals.

Maintenance

In Case the Batteries Were Discharged d WARNING: d CAUTION: When the batteries are removed, horizontally rest the bucket on the ground. Apply the parking brake. Turn the key switch OFF to stop the engine. d CAUTION: When disposing the batteries, consult the shop where you purchased the batteries or professional disposer. Do not irregularly dispose the battery.

• Hydrogen gas is generated from batteries. Inappropriate handling of the batteries may cause fires and/or explosion. Keep tobacco and/or open flame away from the batteries.

• If a metal tool is placed across the battery terminal and a vehicle component such as the engine block, sparks may be created, possibly resulting in fire and/or explosion.

• If electrolyte spills on your skin, scalding and/or blindness may be caused. Wear safety glasses, rubber gloves and a rubber apron whenever handling a battery.

• If electrolyte spills on your skin, immediately flush the skin with plenty of water and then seek immediate medical attention.

• Before checking the batteries, turn the key switch OFF to stop the engine and turn all switches OFF or neutral.

Be careful not to place a metal tool on the batteries. To prevent sparks from flying, first disconnect the negative side (ground line) terminal. When connecting the batteries, connect the negative side terminal last.

Maintenance

Method to Recharge the Removed Battery

• Thoroughly read and understand the operation manual for the battery charger and follow the manual instructions.

• When charging the battery indoors, sufficiently ventilate the area. Remove the battery caps to allow the developed gas to be released.

• During charging the battery, keep fire hazards away from the battery. Do not allow a metal piece to come in contact with the battery terminals.

• After the battery is charged, clean the battery terminals and coat the terminals with grease before installing the battery on the base machine.

Method to Replace with Charged Auxiliary Batteries

• Once the battery has been fully discharged, the service life of the battery is shortened. Replace such batteries with new ones at the earliest opportunity.

• Correctly and securely connect battery plus (+) terminal to cable plus (+) terminal and battery minus (-) terminal to cable minus (-) terminal respectively.

Check Electrolyte Level --- every 100 hours or 1 month

Check the electrolyte level at least once a month.

1. Park the machine on a level ground and stop the engine.

2. Check the electrolyte level.

2.1 When checking the level from the battery side: Clean around the level check lines with a wet towel. Do not use a dry towel. Static electricity may be developed, causing the battery gas to explode. Check if the electrolyte level is between U.L (Upper Level) and L.L (Low level). In case the electrolyte level is lower than the middle level between the U.L and L.L, immediately refill with distilled water or commercial battery fluid.

After refilling, securely tighten the filler plug. Be sure to refill with distilled water before recharging (operating the machine).

2.2 When impossible to check the level from the battery side or no level check mark is indicated on the side: After removing the filler plug from the top of the battery, check the electrolyte level by viewing through the filler port. It is difficult to judge the accurate electrolyte level in this case. Therefore, when the electrolyte level is flush with the U.L, the level is judged to be proper. Then, referring to the right illustrations, check the level. When the electrolyte level is lower than the bottom end of the sleeve, refill with distilled water or commercial battery fluid up to the bottom end of the sleeve.

After refilling, securely tighten the filler plug. Be sure to refill with distilled water before recharging (operating the machine).

2.3 When an indicator is available to check the level, follow the checking results.

3. Always keep the area around the battery terminals clean to prevent battery from discharging. Check terminals for loose and/or rust.

Check terminals for loose and/or rust. Coat the terminals with grease or petroleum jelly to prevent corrosion build up.

Since the electrolyte surface touches the bottom end of the sleeve, the electrolyte surface is raised due to surface tension so that the electrode ends are seen curved.

When the electrolyte surface is lower than the bottom end of the sleeve, the electrode ends are seen straight.

Check Electrolyte Specific Gravity

--- every 250 hours or 3 months

The electrolyte specific gravity varies depending on the electrolyte temperature. The specific gravity should be kept within the range shown below. Charge the battery if the specific gravity is below the limit.

Recommended range of specific gravity by electrolyte temperature fNOTE: Measure the electrolyte specific gravity when the electrolyte temperature is equal to the atmospheric temperature. Do not check the electrolyte specific gravity immediately after operation as the correct value can not be obtained.

I. Brake System

Check Brake Oil Level --- every 10 hours (daily) or when the brake oil indicator comes ON d WARNING: If brake oil low level indicator (1) on the monitor comes ON, immediately stop machine operation, check brake oil tank (2) level and the brake system. Do not continue to operate the machine with the brake oil level reduced, possibly resulting in personal injury or death.

IMPORTANT: When the oil level in brake oil tank (2) becomes lower than [MIN] level, brake oil low level indicator (1) on the monitor comes ON. Immediately stop the machine. Check the brake system for any leaks, and then refill the specified brake oil up to the appropriate level.

IMPORTANT: Refill brake oil with the same brand of oil as described in the “kind of oils”. If oil other than those described in the “kind of oils” is used, malfunction or failure of the brake may result.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Brake oil tank (2) is located at the left front of the engine room. When the brake oil level is correct, it should be between MAX and MIN marks on brake oil tank (2).

3. If the oil level is lower than MIN mark on brake oil tank (2), open cap (3) of brake oil tank (2) and refill specified brake oil up to the appropriate level. After refilling, securely tighten the filler plug.

4. Check that brake oil low level indicator (1) on the monitor does not come ON before operating the machine.

Maintenance

Check Right and Left Brake Interlocking Performance

--- every 10 hours (daily) d WARNING: Put up a No Entrance notice 100 m (109 yd) ahead of the machine forward travel direction. Arrange a safety monitor person. d WARNING: Do not allow dust and/or soil to accumulate in vicinity (3) of the brake pedal. The brake may become inoperable.

While stepping on brake pedal (1), check the pedal movement, the brake performance and the play in the pedal stroke for any abnormality.

If dust and/or soil accumulate in vicinity of the brake pedal, remove the accumulated dust and/or soil.

Check Brake Performance

The machine must be stopped within 5 m (16’ 5” ft·in) range after the brake is applied while driving at the speed of 15 km/h (9.3 mph) on a flat dry paved surface road.

Check Play in Brake Pedal Stroke

Measure the pedal stroke at pedal tip by pressing the pedal with hand until the hand feels an intermittent repulsion from the pedal. Correct play (2): Approx. 10 mm (0.4 in)

If the play is outside the specified range, or abnormal pedal operation and/or performance is noticed, consult your nearest TCM dealer.

Get the machine checked and repaired.

Maintenance

Check Parking Brake Force

--- every 10 hours (daily) d WARNING: Check the machine in a place where no person is present around or ahead the driving direction. Keep bystanders away from the machine.

Park the machine with no load applied on a 15 ° inclined dry surface slope. The machine must not move with the parking brake switch (1) ON.

Should the machine move during inspection, consult your nearest TCM dealer. Get the brake system checked and repaired.

Check Brake Disc (Service and Parking)

--- every 1000 hours or 1 year

Wet disc type service brake and parking brake are mounted on the front axle.

Consult your nearest TCM dealer for checking.

Change Brake Oil

--- every 1000 hours or 1 year

Consult your nearest TCM dealer for changing brake oil.